Flame and smoke retardant vinyl chloride and vinylidene chloride polymer compositions

ABSTRACT

Flame and smoke retardant vinyl chloride and vinylidene chloride polymer compositions are obtained by including therein a compound selected from the group consisting of Si3N4, MoS2 and mixtures thereof.

United States Patent [1 1 Kroenke 1 Oct. 21, 1975 154] FLAME AND SMOKE RETARDANT VINYL CHLORIDE AND VINYLIDENE CHLORIDE POLYMER COMPOSITIONS [75] Inventor: William J. Kroenke, Brecksville,

Ohio

[73] Assignee: The B. F. Goodrich Company, Akron, Ohio [22] Filed: June 24, 1974 [21] Appl. No.: 482,483

Related US. Application Data [62] Division of Ser. No. 438,759, Feb. I, 1974.

[52] US. CL... 260/45.75 R; 260/4224; 260/45.9 R [51] Int. Cl. C08F 6/00 [58] Field of Search 260/45.75 R, 42.24, 45.9 R

[56] References Cited UNITED STATES PATENTS 3,821.151 6/1974 Mitchell 260/4575 OTHER PUBLICATIONS CA Vol. 75, 1971, p. 27, Citation N0. 110,978f.

Primary ExaminerV. P. Hoke Attorney, Agent, or Firm-J. Hughes Powell, Jr.

[57] ABSTRACT Flame and smoke retardant vinyl chloride and vinylidene chloride polymer compositions are obtained by including therein a compound selected from the group consisting of Si N M05 and mixtures thereof.

5 Claims, N0 Drawings FLAME AND SMOKE RETARDANT VINYL CHLORIDE AND VINYLIDENE CHLORIDE POLYMER COMPOSITIONS This is a division of application Ser. No. 438,759 filed Feb. I 1974.

BACKGROUND OF THE INVENTION Vinyl chloride and vinylidene chloride polymers are known to be self-extinguishing and relatively more flame retardant than other polymers such as polyethylene, polypropylene and the like. However, smoke may be produced upon exposure of vinyl chloride and vinylidene chloride polymers to a flame. In addition, improved flame retardancy of these polymers may be desired for applications such as aircraft interiors and the like. Conventional flame retardants such as antimony oxide do not aid in smoke reduction. New vinyl chloride and vinylidene chloride polymer compositions are desired which are capable of both flame retardation and smoke reduction.

SUMMARY OF THE INVENTION Flame and smoke retardant vinyl chloride and vinyli dene chloride polymer compositions are obtained-by including therein a compound selected from the group consisting of Si N M08 and mixtures thereof.

DETAILED DESCRIPTION Vinyl chloride and vinylidene chloride polymers used in this invention include homopolymers, copolymers and blends of homopolymers and/or copolymers. The vinyl chloride and vinylidene chloride polymers may contain from up to about 50% by weight of at least one other vinylidene monomer (i.e., a monomer containing at least one terminal CH C group per molecule) copolymerized therewith, more preferably up to about 20% by weight of such monomer. These monomers include 1 olefins having from 2 to 12 carbon atoms, more preferably from 2 to 8 carbon atoms, such as ethylene, propylene, l-butene, isobutylene, lhexene, 4-methyl-l-pentene and the like; dienes having from 4 to carbon atoms including such conjugated dienes as butadiene, isoprene, piperylene and the like; ethylidene norbomene and dicyclopentadiene; vinyl esters and allyl esters such as vinyl acetate, vinyl chloroacetate, vinyl propionate, vinyl laurate, allyl acetate and the like; vinyl aromatics such as styrene, a-methyl styrene, chlorostyrene, vinyl toluene, vinyl naphthalene and the like; vinyl and allyl ethers and ketones such as vinyl methyl ether, allyl methyl ether, vinyl isobutyl ether, vinyl n-butyl ether, vinyl chloroethyl ether, methyl vinyl ketone and the like; vinyl nitriles such as acrylonitrile, methacrylonitrile and the like; cyanoalkyl acrylates such as a-cyanomethyl acrylate, the a-, B- and y-cyanopropyl acrylates and the like; olefinically unsaturated carboxylic acids and esters thereof, including a, B-oletinically unsaturated acids and esters thereof such as methyl acrylate, ethyl acrylate, chloropropyl acrylate, butyl acrylate, hexyl acrylate, 2- ethylhexyl acrylate, dodecyl acrylate, octadecyl acrylate, cyclohexyl acrylate, phenyl acrylate, glycidyl acrylate, methoxyethyl acrylate, ethoxyethyl acrylate, hexylthioethyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, glycidyl methacrylate and the like, and including esters of maleic and fumaric acid and the like; amides of the a, B-olefinically unsaturated carboxylic acids such as acrylamide and the like; divinyls, diacrylates and other polyfunctional monomers such as divinyl benzene, divinyl ether, diethylene glycol diacrylate, ethylene glycol dimethacrylate, methylene bis-acrylamide, allyl pentaerythritol, and the like; bis(,B-haloalkyl) alkenyl phosphonates such as bis(B-chlorethyl)vinyl phosphonate and the like; and the like.

More preferred monomers include l-olefins having from 2 to 12 carbon atoms, more preferably from 2 to 8 carbon atoms, such as ethylene, propylene, l-butene, isobutylene, l-hexene, 4-methyl-l-pentene and the like; vinyl esters and allyl esters such as vinyl acetate, vinyl chloroacetate, vinyl propionate, vinyl laurate, allyl acetate and the like; olefinically unsaturated carboxylic acids and esters thereof, including a, B-olefmically unsaturated acids and esters thereof such as methyl acrylate, ethyl acrylate, chloropropyl acrylate, butyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, dodecyl acrylate, octadecyl acrylate, cyclohexyl acrylate, phenyl acrylate, glycidyl acrylate, methoxyethyl acrylate, ethoxyethyl acrylate, hexylthioacrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, glycidyl methacrylate and the like, and including esters of maleic and fumaric acid and the like; and amides of a, B-olefinically unsaturated carboxylic acids such as acrylamide and the like.

The Si N or M08 additive compounds or mixtures thereof used in this invention are polycrystalline or amorphous materials having an average particle size from about 100 microns to about 0.5 micron, more preferably from about 40 microns to about 0.5 micron. Acicular single crystals (whiskers) are not desired because they disperse less readily and are substantially more expensive. The additives used in this invention are all colored compounds. Polymer compositions containing them may have colors similar to, although somewhat lighter than, the compounds themselves.

The additive compounds are used in amounts from about 0.5 weight parts to about 10 weight parts per 100 weight parts of polymer. The amount used may be varied to obtain a proper balance of flame retardancy and smoke retardancy. Use of more than about 10 parts by weight of additive per 100 parts by weight of polymer probably will affect adversely other important physical properties, such as tensile strength and the like.

The vinyl chloride and vinylidene chloride polymers may be prepared by any method known to the art such as by emulsion, suspension, bulk or solution polymerization. The additive compounds may be mixed with the polymer emulsion, suspension, solution or bulk mass before monomer recovery and/or drying. More preferably the compounds may be mixed with dry granular or powdered vinyl chloride or vinylidene chloride polymers. The polymer and compound may be mixed thoroughly in granular or powder form in apparatus such as a I-Ienschel mixer and the like. Alternatively, this step may be eliminated and the mixing done while the polymer mass is fluxed, fused and masticated to homogeneity under fairly intensive shear in or on a mixer apparatus having its metal surface in contact with the material. The fusion temperature and time will vary according to the polymer composition and level of additive compound but will generally be in the range of about 300 to 400F and 2 to 10 minutes.

Flame and smoke retardancy may be measured using the Goodrich Smoke OI Test. The test results correlate well to the Oxygen Index (ASTM D2863-). The

test results also correlate to NBS Smoke Chamber date (ASTM STP 422, pp. 166-204) over the full NBS Smoke Chamber test range. Generally A X 6 X 0.075 in. strips for plasticized polymers. The Goodrich O1 testing is performed in a standard Oxygen lndex test chamber (described in ASTM D2863-70) modified to permit the smoke from the burning sample to rise in the vertical chimney and pass through the light beam of an integrating spectrophotometer. The integrated area provides a measure of the amount of smoke generated by a burning sample.

Mass loss rate (m grams/minute) for the Goodrich Smoke 01 Test are determined at five or more different oxygen concentrations and plotted against these concentrations. Linear regression analysis is used to find the mass loss rate curve that best fits the data; correlation coefficients are at least 0.90 and generally about 0.95. The Goodrich 01 number is the oxygen concentration at which m 0.3 grams/minute. Successive tests of a given composition have a reproducibility of about i 1% oxygen. A Goodrich smoke number (D l/cm) is calculated using the formula for the point on the mass loss rate curve where m is a constant (0.6 grams/min). Suitable flame and smoke retardant compositions have substantially higher Goodrich Ol numbers and lower Goodrich smoke numbers than control samples.

Smoke retardancy and char enhancement may be measured quickly using the Goodrich Smoke-Char Test. Small (0.3-0.4g) polymer samples measuring about k X X 0.075 in. are placed on a screen and burned with a propane gas flame rising vertically from beneath the sample. Sample geometry at a constant weight has been found not to be significant for the small samples used in this test. A Bernz-O-Matic pencil flame burner head is used with gas pressure maintained at 40 psig. The sample is immersed totally and continuously in the flame. Smoke from the burning sample rises in a vertical chimney and passes through the light beam of a Model 407 Precision Wideband Photometer (Grace Electronics, Inc., Clevland, Ohio) coupled with a Newport Photometer integrator. Other integrating spectrophotometers also may be used. The smoke number, S is a measurement of smoke generation as integrated area per gram of polymer in the sample compound.

The residue or char remaining after the Goodrich Smoke-Char Test is weighed and used to calculate the percent of backbone char BC), which takes into account nonburnable residues identified, for example, by X-ray diffraction analysis. BC is, therefore, a measurement of polymer resistance to burning. Increased char after burning indicates increased flame resistance. The following formula is used to calculate percent of backbone char from the indicated variable weights:

actual char expected nonburnable residues BC compound wt. nonPVC ingredients HCl content of PVC are desirable, such as in plastic components for air-. plane interiors, childrens toys, house siding1and the like. Of course, overall suitability for a particularuse will depend upon other factors as well, such as comonomer type and level, compounding ingredient type and level, polymer particle size. etc.

The following examples illustrate the present invention more fully.

EXAMPLE 1 The following recipe was used:

MATERIAL PARTS Polyvinyl Chloride l 100 Polyethylene Powder Processing Aid 2 Dibutyl tin bis(isooctylthiogly- 2 collate)stabilizer Si N or M05 (2) 10 (1) Homopolymer having an inherent viscosity of about 0.94

0.99; ASTM classification GPA-15443. (2) The control sample contained neither si N, nor M05 Each experimetnal sample was prepared by blending the above materials using an Osterizer blender. Thd dibutyl tin bis (isooctylthioglycollate) was added in'four 0.5g portions to the other materials with 15 second intervals between each addition. The samples were then milled on a two-roll mill for about 3 minutes at a roll surface temperature of about 320F. The milled samples were pressed into 6 X 6 in. X 0.07 5 in. sheets at about 330F. using 40,000 lbs. of force applied to a 4 in. ram. The samples were given a 3-minute preheat prior to pressing for 6 minutes under full load.

The molded samples were cut into'% X 6 X 0.075

strips and tested using the Oxygen Index (ASTM D2863-) and Goodrich Smoke 01 tests described heretofore. Test results are given in Table [i '01 at m 0.3g/min. *D at m 0.6g/min.

These results demonstrate that Si N 'and MoS substantially retard flame and smoke during b'urning of rigid polyvinyl chloride in the oxygen-enriched atmosphere used for the ASTM D2863-70 Oxygen Index and Goodrich Smoke Ol tests.

EXAMPLE 2 The following recipe was used:

(l) Homopolymer having an inherent viscosity of about 0.94 0.99; ASTM (lassificalion GPA-15443. (2) The control sample contained neither Si N nor MoS Each experimental sample was prepared by blending the above materials using an Osterizer blender. The dibutyl tin bis (isocctylthioglycollate) was added in four 0.5 g portions to the other materials, with second intervals between each addition. The samples were then milled on a two-roll mill for about 3 minutes at a roll surface temperature of about 320F. The milled samples were pressed into 6 X 6 X 0.075 in. sheets at about 330F using 40,000 lbs. of force applied to a 4-inch ram. The samples were given a 3-minute preheat prior to pressing for 6 minutes under full load.

The molded samples were cut into 0.3 0.4 gram samples (about /z X /8 X 0.075 in.) and tested using the Goodrich Smoke-Char test described heretofore. Test results are given in Table II:

MoS l() 83 26 23.39 760 Weight Parts of additive per weight parts of polyvinyl chloride. "Lower S indicates less smoke formation. ""7: Backbone Char discussed heretofore at pp. 6-7.

These results demonstrate that Si N and MoS at 10 part levels substantially reduce smoke evolution and enhance char formation during forced burning of rigid polyvinyl chloride in the Goodrich Smoke-Char test. A 1 part level of M08 is substantially less effective in smoke reduction but still enhances char formation.

I claim:

1. A flame and smoke retardant composition comprising l) a vinyl chloride or vinylidene chloride polymer and (2) a mixture of M08 and Si N said mixture being presnet in an amount from about 0.5 to about 10 weight parts per 100 weight parts of polymer and having an average particle size from about 100 microns to about 0.5 micron. I

2. A composition of claim 1 wherein said polymer contains copolymerized therewith up to about 50% by weight of at least one other vinylidene monomer containing at least one terminal CH =C group per molecule.

3. A composition of claim 2 wherein said polymer contains copolymerized therewith up to about 20% by weight of said other vinylidene monomer.

4. A composition of claim 3 wherein said vinylidene monomer is selected from the group consisting of lolefins having from 2 to 12 carbon atoms, vinyl esters, a,,B-olefinically unsaturated carboxylic acids and esters thereof, amides of a,,B-olefinically unsaturated carboxylic acids, and esters of fumaric and maleic acid.

5. A composition of claim 4 wherein. said compound has an average particle size of from about 40 microns to about 0.5 micron.-

UNITED STATES PATENT OFFICE QETIFICATE OF QGRRECTIUN PATENT NO. 3,91%,201 DATED October 21, 1975 INVENTOR( 1 William J. Kroenke It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 3 line 1, "date" should read ------data----; line t, after in. insert; ---strips are used for testing rigid polymers and l/8 in. X 6 in. X l/ t in.-. Column t, lin 35, Thd should read -The---. Column 5, line 16, "(isocctylthioglycollate)" should read --isooctylthioglycollaoe---. In Table II in column 5, under Smoke Formation should be Reduction-n Colurm 6, line 16 "presneo" should read ---present---.

[SEAL] A ttest.

RUTH C. MASON Hum-ting Officer C MARSHALL DANN (ummissrmwr uf Parents and' Trademarks twenty-seventh D 3} 0f April 1 9 76 

1. A FLAME AND SMOKE RETARDANT COMPOSITION COMPRISING (1) A VINYL CHLORIDE OR VINYLIDENE CHLORIDE POLYMER AND (2) A MIXTURE OF MOS2 AND SI3N4, SAID MIXTURE BEING PRESENT IN AN AMOUNT FROM ABOUT 0.5 TO ABOUT 10 WEIGHT PARTS PER 100 WEIGHT PARTS OF POLYMER AND HAVING AN AVERAGE PARTICLE SIZE FROM ABOUT 100 MICRONS TO ABOUT 0.5 MICRON.
 2. A composition of claim 1 wherein said polymer contains copolymerized therewith up to about 50% by weight of at least one other vinylidene monomer containing at least one terminal CH2 C< group per molecule.
 3. A composition of claim 2 wherein said polymer contains copolymerized therewith up to about 20% by weight of said other vinylidene monomer.
 4. A composition of claim 3 wherein said vinylidene monomer is selected from the group consisting of 1-olefins having from 2 to 12 carbon atoms, vinyl esters, Alpha , Beta -olefinically unsaturated carboxylic acids and esters thereof, amides of Alpha , Beta -olefinically unsaturated carboxylic acids, and esters of fumaric and maleic acid.
 5. A composition of claim 4 wherein said compound has an average particle size of from about 40 microns to about 0.5 micron. 